The Changing Refrigerant Landscape

(Minefield?!)

John WithouseSr. Principal Engineer, Sporlan Division of Parker-Hannifin

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Today’s Topics

• Drivers for Change

• Regulatory Actions

• R22 – The Final Countdown!

• EU F-gas Laws

• US EPA SNAP Rules

• SNAP Determinations of Acceptability

• Section 608 Refrigerant Management

• Montreal Protocol Amendment

• The Alternatives

• HFO’s and Blends

• Hydrocarbons

• Future Trends

• Refrigerant Roadmap

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Drivers for Change

• #1 Concern: HCFCs deplete atmospheric ozone, HCFCs & HFCs

have high Global Warming Potential (GWP)

• Baseline for GWP is CO2, set at 1

• Example GWPs: R404A=3922, R410A=2088, R134a=1430

• For R22, ODP=0.055 (5.5% of R12), GWP=1810

• Aggressive F-gas regulation now law in Europe

• US EPA SNAP actions

• Pending de-listing of many HFCs

• Recent or pending approval of new refrigerants

• Montreal Protocol

• Treaty ratified by all UN member nations that established phase-outs of

CFCs, then HCFCs

• Now amended to include HFCs

• “Green” sells!

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HCFC Phase-outs, EU and North America

• Worldwide, driven by the Montreal Protocol

• EU R22 phase-out for HVACR is complete.

• Began several years ahead of US.

• Total ban on even reclaimed refrigerant as of 1/1/2015.

• Only service activity with R22 is reclamation for destruction.

• US R22 phase-out for HVACR now in latter stage.

• Ban on shipment of units containing R22 since 1/1/2010, but no use ban.

• Ban on shipment of TEV power elements containing R22 since 1/1/2015.• No ban on use of existing elements for a distributor, contractor or OEM – but manufacturers

can’t make or ship any more of them.

• Sporlan TEV elements for R22 applications shipped since late 2014 do not contain any R22.

• 2015-20 production phase-down schedule set 10/16/2014. (chart next slide)

• “Dry” units still being shipped, though there have been petitions to end this.

• 2015-20 final rule does not address dry-ship units, but does promise review

of shipments from 2008-2015, and leaves open possibility of future ban.

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US HCFC R22 Phase-out, 2013 - 2020

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2011 was 110

million lbs

EU F-gas Regulation:HFC Phasedown, other new requirements begin

• Now law, per Regulation (EU) No. 517/2014 of the European

Parliament.

• Became law in October 2014, began phasing into effect 1/1/2015

• Establishes GWP limits and timelines to meet those limits for several

different classes of equipment.

• GWP < 150 by 2022 for self contained refrigeration

• GWP < 150 by 2022 for commercial systems (high side of cascades GWP < 1500)

• GWP < 750 by 2025 for split system A/C with charge < 3kg

• Sets requirements for labeling, periodic leak checks, repair, record

keeping, and reporting.

• Requires leak monitoring systems on systems larger than 500 tons-

equivalent CO2 charge (~300 lbs R404A, ~600 lbs R407F)

• Requires certified personnel and companies for service and end-of-life

recovery.

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Recent US EPA ActionsFocus turns from HCFCs to HFCs

• SNAP changes – 3 final rules

• Final (effective 5/11/2015) – adds R32, R170, R290, R441A, &

R600a for home & light commercial A/C, stand-alone food retail,

vending, others, implements charge limits for A2L & A3 refrigerants.

• Final (effective 7/20/2015) – eliminates R404A & R507 from most

commercial applications, R134a & others from limited applications

• Final (effective 12/1/2016) – lists R290 for new applications;

formally bans several highly flammable R22 alternates from auto,

residential, & chillers; sets timetable for phase-out of R134a,

R407C, R410A & others from chillers (2024); R404A, R507, &

others from some industrial (2023) & domestic refrigeration (2021)

applications

• US EPA SNAP website:

http://www.epa.gov/snap/

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Final Rule to de-list HFCsSummary of de-listing

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Table continues next slide…

Final Rule to de-list HFCsSummary of de-listing (continued)

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Recent EPA SNAP ApprovalsNew HFO-blend and CO2 applications acceptable

• Several refrigerants determined acceptable by technical

review

• 10/21/2014 - R450A for a very wide range of applications, CO2 for

transport refrigeration

• 7/16/2015 - R513A for a very wide range of applications

• 7/16/2015 - R448A & R449A for supermarket, low-temp stand-

alone & others

• 5/23/2016 – adds new CO2 applications, lists R1336mzz & R514A

for A/C & chiller applications

• 9/26/2016 – R448A & R449A for retail food processing and

dispensing, R449B for same applications as R448A & R449A

• Additional approvals expected, but nothing announced yet

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EPA Rule Changes, non-SNAPChanges to Section 608 Requirements• US EPA released changes to Refrigerant Management Requirements

under CAA Section 608 on 9/26/2016. Major provisions:

• Extend the requirements of the Refrigerant Management Program to cover substitute

refrigerants, including HFCs.

• Hydrocarbons already exempted from Section 608 requirements remain exempted

• Leak rate repair threshold: annual rate above which refrigeration and air conditioning

equipment normally containing 50+ lbs. of refrigerant must be repaired:

• Lower from 35% to 30% for industrial process refrigeration (IPR)

• Lower from 35% to 20% for commercial refrigeration equipment

• Lower from 15% to 10% for comfort cooling equipment

• Require regular leak inspections or continuous monitoring devices for refrigeration or

air conditioning systems that have exceeded the above leak limits:

• Annual inspections for systems normally containing 50+ lbs. of refrigerant

• Quarterly inspections for commercial refrigeration and IPR systems normally containing

500+ lbs.

• Systems normally containing 50+ lbs. of refrigerant that have leaked 125% or more of

their full charge in a 12 month period must be reported to EPA.

• Require technicians to keep a record of refrigerant recovered during system disposal

from systems with a charge size from 5–50 lbs.

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Montreal Protocol Amended to Include

HFCs

• Meeting of the Parties in Kigali, Rwanda October 8-14, 2016

• Agreements reached and finalized

• Signed by all parties

• Lists 18 HFC’s as a new Annex F

• Does not include HFO’s, but does include R32

• Phases down to 15% plateau from baseline, on GWP-weighted basis

• Not a complete phase-out.

• Licensing of HFC imports and exports, and import and export

controls for non‐Parties.

• Reporting of production, consumption, and byproduct emissions.

• Recognizes three groups of nations, with different timelines

• 2/3 majority of Senate must approve to be ratified by the US

• AHRI has committed to push for approval

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Montreal Protocol HFC Phasedown Timeline

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It appears that the EU would have a higher eventual plateau than the rest of the world at 20% versus 15%. However, their baseline calculated using earlier years will likely lead to it being nearly the same as the other non-A5 countries. The F-gas laws carry provisions for regular progress review and revision if necessary, so there is already a mechanism in place for adjustment on the EU’s part. There are also slight variances in steps and timeline for a few smaller countries that were negotiated into the amendment.

Alternates: An Overview

• Lower-GWP HFC blends, such as:

• R407A, GWP = 2107 and R407F, GWP = 1824

• Commonly used as retrofits for R22 and R404A/R507

• R32, GWP = 675, showing promise as R410A alternate

• Honeywell/DuPont joint venture to develop HFO’s:

• R1234yf & R1234ze(E) both ODP=0, GWP’s recently revised to

“below 1” – synthetics with lower GWP than naturals!

• R1234yf adopted for automobile A/C beginning 2013 model year

in US & EU - very similar thermodynamically to R134a

• Low pressure, low volumetric capacity > need to blend with

others to match capacity of current HFC blends.

• Natural Refrigerants:

• Carbon Dioxide (CO2), Hydrocarbons, Ammonia (NH3)

• All GWP’s ~3 or less, all with other challenges

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HFO’s and blends, R134a-like

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R134a-like HFO’s & blendsNotes & Observations

• Pure HFO’s:

• R1234yf very similar to R134a, both P-T and thermodynamically

• R1234ze is lower pressure and capacity than yf & R134a, but is a good

choice in chillers (good efficiency)

• Both still high cost, but ze is less costly to produce than yf – new production

capacity for both online recently or in near future

• Blends:

• R513A is an azeotrope, R450A glide is very low

• R450A and R513A EPA SNAP-approved for a wide range of applications

• Bitzer and Copeland support both R450A and R513A

• Commercially available in EU, Canada, and US.

• Manufacturers focusing on promoting these, rather than developing

additional R134a alternatives

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R404a-like Blends

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R404A-like BlendsNotes & Observations

• R407A & F primarily for supermarket – eliminated by EPA for stand-alone

• Capacity and efficiency of R407F higher than R404A and R407A in many

published tests, but also higher discharge temp and cost

• R448A and R449A approved for supermarket, low-temp stand-alone food retail,

transport refrigeration, and ice machine applications

• R448A & R449A higher discharge temps, but also higher capacity and efficiency

vs R404A per most published tests

• Several successful field trials of both

• Bitzer and Copeland support both R448A and R449A

• Significantly increasing retrofit activity from both R22 and R404A

• On a per-unit-capacity basis, for R448A or R449A:

• ~25% lower mass flow than R404A, liquid volumetric flow is ~30% lower

• ~10% higher mass flow than R22, liquid volumetric flow is ~15% higher

• Existing R404A TEVs may be oversized, Existing R22 TEVs may be OK

• Suction volumetric flow is 5 – 15% higher for R448A or R449A vs R22 or R404A

• Existing suction side valves (EPR, EEPR, Solenoid, etc.) probably OK

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Refrigerant Blends with GlideIllustration of “Glide”

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Refrigerant Blends with GlideGlide and the Pressure-Enthalpy Diagram

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Blends with High GlideSubcooling and Superheat Calculations

On the previous P-h diagram, an R407A system is operating at

measured conditions of Phigh = 252 psia and Plow = 57 psia. Using the

proper saturation states:

Liquid Subcooling Calculation:

Measured liquid line temperature = 80°F

From NIST Refprop, R407A bubble point @ 252 psia = 100°F

Liquid Subcooling = 100°F – 80°F = 20°F

Suction Superheat Calculation:

Measured suction gas into the compressor = 65°F

From NIST Refprop, R407A dew point @ 57 psia = 20°F

Suction Superheat = 65°F – 20°F = 45°F

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Blends with High GlideSubcooling and Superheat Calculations (cont.)

• What if we use the wrong saturation state?

Suction Superheat Calculation:

Measured suction gas into the compressor = 65°F

From NIST Refprop, R407A bubble point @ 57 psia = 10°F

Suction Superheat = 65°F – 10°F = 55°F

• We calculate an additional 10°F of superheat that does not exist.

• We can see this is incorrect by checking against the P-h diagram

• The closest saturation state is dew point, not bubble point.

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R410A Alternates

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R410A AlternatesNotes & Observations

• Primarily for A/C & heat pump applications

• R32:

• Capacity is somewhat higher, charge is significantly lower

• Discharge temps have been measured 8 – 30°C higher in drop-in tests

• Heavily promoted by Daikin, other Asian manufacturers adopting

• Daikin/Goodman has US production and sales of R32 units

• R447A:

• Lower in both pressure and capacity

• Per Honeywell, a product for EU, not US at this time

• R452B:

• Equal capacity to R410A, ~5% higher efficiency

• Still A2L safety classified, but noticeably lower flammability than R32

• Low glide, <2°F

• Heavy marketing push by Chemours

• Submitted to SNAP, approval expected

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Hydrocarbon RefrigerantsCompared with similar existing HCFC’s/HFC’s

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Medium Pressure Low Pressure

HydrocarbonsNotes & Observations

• R600a (isobutane) widely used in place of R134a in EU home

appliances, increasing use in US as well

• Low pressures, but very good capacity and efficiency

• R290 (propane) is a very good replacement for R22

• However, retrofits of existing systems not allowed – serious safety issue!

• Compatible with mineral oil – synthetic not required

• R290 has much higher capacity, slightly higher COP than R22 – enables:

• Small charges

• Highly efficient systems

• All are A3 (highly flammable), thus restricted to very small charges in US

• Propylene has good thermodynamic properties, but:

• Some material & oil compatibility difficulties

• Air quality concerns - may not be approved in the US

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Future Trends

• Non-flammable retrofits for R404A important in the near term. R407A, R407F are in widespread use.

• R448A and R449A are rapidly gaining momentum in new equipment and retrofits, R449B also now an option.

• R450A and R513A are lowest GWP that remain A1 safety classified, but are less suitable for low temp.

• R290 in self contained, R600a in home appliances

• Some A2L, <150 GWP blends to replace R404A (R454C, R455A, R457A) are coming onto the scene.

• CO2 will continue to become more important.

• R407A & R407C as replacements for R22 near term.

• Many R41x, R42x, R43x blends for R22 retrofit.

• R410A will remain in the market for some time.

• R32, R452B, and others gaining traction, but are A2L.

• Long term mix is less clear, but likely to include HFO blends and naturals, depending on market area.

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Refrigeration

Air

Conditioning

Refrigerant Roadmap

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Thank You!

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